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<p>Laser-based powder bed fusion of polymers (PBF-LB/P) has emerged as a leading additive manufacturing technology, enabling the production of complex geometries and customized parts. Although significant research has focused on optimizing process parameters such as laser power, scan speed, and energy density, the influence of positional factors -specifically the placement and orientation of parts on the build platform- remains comparatively underexplored. This study proposes a novel method to analyse the positional effects through a full factorial design, wherein 27 parts were produced and characterized using X-ray computed tomography (CT) and thermal imaging. The integration of these advanced techniques provides a new unified framework for evaluating critical quality metrics, including dimensional deviations and pore characteristics, establishing the relationships between positional factors, layer-wise bed thermal and defect formation. The development of specialized graphical tools enhances the visualization and interpretation of cross-relationships. Results demonstrate that positional parameters, together with thermal variations recorded as a covariate, significantly affect both the external geometry and internal defect formation of the parts. Overall, the proposed procedure advances the current understanding of the influence of positional and thermal conditions on part quality in PBF-LB/P processes. This enriched knowledge supports future efforts to optimize nesting strategies and improve production performance.</p>

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Positional effects in polymer laser powder bed fusion: investigating dimensional accuracy and internal defects through integrated X-ray computed tomography and in-process thermal imaging

  • 期刊论文

  • 发表日期：

    2026年2月26日

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  • Javier Sánchez-Prieto,
  • Ricardo Santander,
  • Filippo Zanini,
  • Michele Pavan,
  • Simone Carmignato

摘要

Laser-based powder bed fusion of polymers (PBF-LB/P) has emerged as a leading additive manufacturing technology, enabling the production of complex geometries and customized parts. Although significant research has focused on optimizing process parameters such as laser power, scan speed, and energy density, the influence of positional factors -specifically the placement and orientation of parts on the build platform- remains comparatively underexplored. This study proposes a novel method to analyse the positional effects through a full factorial design, wherein 27 parts were produced and characterized using X-ray computed tomography (CT) and thermal imaging. The integration of these advanced techniques provides a new unified framework for evaluating critical quality metrics, including dimensional deviations and pore characteristics, establishing the relationships between positional factors, layer-wise bed thermal and defect formation. The development of specialized graphical tools enhances the visualization and interpretation of cross-relationships. Results demonstrate that positional parameters, together with thermal variations recorded as a covariate, significantly affect both the external geometry and internal defect formation of the parts. Overall, the proposed procedure advances the current understanding of the influence of positional and thermal conditions on part quality in PBF-LB/P processes. This enriched knowledge supports future efforts to optimize nesting strategies and improve production performance.